FEBRUARY 2017New sletter

NEW 1010 Smooth Series Bars

Mounting & Hex Tools Issue Tabletop Materials,

New 1010-S ProfilesTabletop MaterialsMounting TabletopsHex Tools

All About TabletopsThis edition of EBN provides information about tabletops, materials, how to mount them, the concept of “pre-loading” (which we use here in our assembly department), and the basic hex tools required for assemblying t-slots. This issue also has an overview of the new 1010 smooth series - 15 new bars that give you one more alternative for designing t-slot structures.

While tabletops, doors, shelves and side panels can be made from the same materials, certain materials are better suited for tabletops. This document should help you understand these materials better.

Key Materials Attributes: Thickness Stength Heat Resistance UV/Sunlight Resistance Safety Color Price

Note: Note: The thickness and strength of your tabletop and shelf materials will have an effect on the frame design. For example, if you have a long 30” x 72” table - the number of cross braces under the tabletop will be more for thin tabletop materials and less for thick tabletop materials. Sometimes, paying more for a thicker tabletop will decrease the frame costs, and sometimes increasing the framing will allow you to use thinner materials while still achieving the same structural strength target.

ExtrusionBuilder News is a free newsleer for people that build frames using T-sloed aluminum extrusions and components. It is designed to be both informave and helpful for both professional builders/assemblers and “do-it-yourselfers”.

EExtrusionBuilder News is published by F&L Industrial Soluons, Inc. - a designer and builder of professional industrial framing using T-sloed aluminum extrusion. F&L Industrial Soluons uses 80/20’s line of aluminum products, and is proud to be an authorized full-service, Tier-1 80/20 distributor. We feel 80/20 offers the largest, most complete line of T-slot components in the world, with the higheworld, with the highest quality at the best price. So even though you may find references to 80/20 T-slot profiles and components throughtout this newsleer, most informaon should be applicable - even if you use a different brand/line of T-sloed aluminum extrusion. Our goal is to publish a newsleter that is useful for everyone that builds using T-sloed aluminum eextrusion. Thanks for reading and enjoy!

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What’ Inside? New 1010 Smooth Series Profiles . . . . . . . . . 3Common materials for tabletops . . . . . . . . . . 4Flush Mounng Tabletops . . . . . . . . . . . . . . . 6Hidden Mount Tabletops . . . . . . . . . . . . . . . . 7Hex Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCEEvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCStore Discount . . . . . . . . . . . . . . . . . . . . . . . . . BC

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New 1” x 1” Smooth Profiles - 1010-S SeriesIn the past, if you wanted a smooth-sided 1” x 1” bar, you were forced to use 25-2525 - the 25 metric series bars. Not anymore. 80/20 has finally filled in the 10 Series line of 1” x 1” profiles with 10 new smooth-sided bars as shown below.

Please notice that the new bars include 4 close-sided bars (1001-S, 1002-S, 1003-S, 1004-S).

All bar/profiles shown above are now available for purchase. Specifications for these new bars are show in the new Catalog 21. Or you can download the Addendum for Catalog 20 from the download section of the F&L Industrial Solutions website (www.fandl8020.com).

The original 10 Series bars feature the align-a-groove finish that makes aligning 90o bars easier and straight. However, many people prefer the look of the smooth series.

Pricing for the smooth bars is exactly the same as for the original 10 series bars, so choose the one you like best.

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Common Materials For TabletopsPhenolic Resin: A decorative durable surface with exceptional impact and scratch resistance. It is a versatile option that resists moisture and dirt accumulation, making it easy to clean. It is commonly used for interior applications such as work surfaces and table or desk tops in offices and laboratories. #1 for Labs.

HDPE:HDPE: A strong, corrosion resistant option that provides durability and resists warping. It has a texture on both sides, which masks scratches and marks. The surface layer has a dot pattern texture that inhibits slippage and promotes water drainage. HPDE panels are chemical and impact resistant, and feature a special high-friction, polymer surface that is environmentally stabilized to resist harsh sun and sea conditions, including ultraviolet light. A great solution in a wide range of indoor/outdoor applications.

ABS:ABS: Cost effective material with one smooth side and one haircell (textured side) which hides scratches and marks. It provides impact resistance and is stable up to 180 degrees Farenheit. ABS is an ideal material for structural applications when impact resistance, strength, and stiffness are required. It is easy to paint and glue and is FDA compliant for use in food processing applications.

Aluminum: Made of 6061-T6 aluminum alloy that comes in an unanodized mill finish. It is a strong durable option that is often used industrial tabletops. It offers superior weight-to-strength ratio over stainless steel and superior anti-corrosive properties. It can also be anodized or powdercoated.

Hybrid Metal:Hybrid Metal: A composite featuring a plastic core and thin aluminum skins on both sides makes this material a light yet durable option. This panel is stable up to 125 degrees Fahrenheit and is weather resistant, making it suitable for indoor and some outdoor applications. Available in multiple colors.

Laminated Wood: Laminate tabletops usually have a vinyl laminate surface that provides an aesthetic appearance with an internal core made of particle board. They are commonly used for indoor applications such as kitchen countertops, workstations, desks and tables.

Indoor Tabletop Materials By Popularity:

1. Phenolic Resin2. HDPE3. ABS4. Aluminum Composite5. Aluminum6. Lamin6. Laminated Wood

Outdoor Tabletop Materials By Popularity:

1. HDPE2. Aluminum Composite3. Aluminum4. Hybrid Metal5. ABS

The data above is strictly the opinion of F&L Industrial Soluons and is meant as a very general guide. We highly recommend reading the technical specificaons from the manufacturer for further informaon.

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Phenolic Resin

Wood Laminate

HDPE

Aluminum Composite

ABS

Aluminum Plate

Mounting Tabletops - Method #1 - Flush MountFlush Mount with Flathead Bolt & Drop-In T-Nut This mounting method is the most common for lab tables, work benches, desks, tables, counters, carts, etc.

This method requires countersinking holes through the This method requires countersinking holes through the tabletop.Countersunk holes have a tapered shape that will fit the flathead bolt and create a flat, professional surface look.

Step 1:Step 1: Determine the number of holes you need to mount your tabletop, and their location. Here is how we do this. First, we assign 4 bolt locations to the corners (assuming you have a rectangular or square tabletop). Next, we add additional bolts if the length or width of the table is over 24”. For example, we would only use 4 bolts on a 24” x 24” table. But on a table that is 24” x 48” - we would use 6 bolts. If the table size isn’t in nice 24” - we would use 6 bolts. If the table size isn’t in nice 24” increments, make sure you center out the holes you add between the corners to it looks balanced. Once you know how many holes you need, mark their locations on your tabletop.

Step 2: Drill the proper size hole for your flathead bolt size all the way through the tabletop. No hole in the bar or frame is required.

Step 3:Step 3: Using a countersink bit and the same centerline you used for the holes, countersink each hole. The most important thing to remember is you must set the depth just right or your countersunk hole will be too small or too large. If you are not using a drill press, create some type of jig to prevent the bit from going to deep in the table top.

Step 4:Step 4: Pre-load all the bolts and t-nuts on the tabletop. Step 5:Step 5: Now set the tabletop on top of the frame. It won’t lay flat because the t-nuts are not aligned with the slot. Now using a pencil with the eraser side, rotate the t-nuts until they are aligned with the slot below. If you do this right, your tabletop will drop down flat on the bar as you go around the table.

Step 6:Step 6: When the entire tabletop is laying flat on the frame, tighten each bolt until tight.

Flathead Bolt

Economy Drop-In T-Nut

Tabletop

This method requires a countersink (a tapered hole) drilled through the tabletop

Pre-Loading Bolt & Nut On Tabletop

Tabletop

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Frame

Mounting Tabletops - Method #2 - Hidden MountHidden Mount with Flathead Bolt & Drop-In T-Nut This mounting method is the preferred method if tabletop needs to be clear of any mounting hardware.

This method requires mounting 2 hole inside corner This method requires mounting 2 hole inside corner brackets to the upper frame, just underneath the tabletop and then screwing into the tabletop to secure the top.

Holes can be pre-drilled in some thicker tabletop Holes can be pre-drilled in some thicker tabletop materials, or HeliCoils mounted in the underside of the top to facilitate attachment. In these cases, using a 2 hole slotted bracket would allow you to movement in 2 directions in case the hole was not prefectly positioned.

Step 1:Step 1: Mount 2 hole inside corner brackets around the inside of the upper most frame (the framing that will support the tabletop).

Step 2: If tabletop is to be pre-drilled or outfitted with HeliCoils, then identify the placement of your brackets and drill holes in the underside of the tabletop. If no pre-drilling is to be done, then skip to Step 3.

Step 3:Step 3: Place the tabletop on the frame and align it to its proper position. If holes are pre-drilled, loosen and align your 2 hole brackets with the holes.

Step 4:Step 4: Carefully install screws on opposite ends of the tabletop to prevent unwanted table movement. Check to make sure all holes line up, and that all brackets have a clear pathway to the bottom of the tabletop. Step 5:Step 5: Finish installing all screws through remaining 2 hole brackets.

2 Hole Slotted Inside Corner Brackets Pre-Mounted To Upper Frame

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HEX TOOLSBuilding t-slot extrusion frames is pretty easy once you learn the basics, and if you have the right tools. One of the great things about t-slot bars and fasteners is that you only need a few tools to build almost anything. All you need is the right size hex wrench (allen wrench) - ideally with a ball-end. Here are the main 2 types:

Ball-End T-Handle Hex WrenchesThese easy-to-useThese easy-to-use T-handle wrenches allow you to tighten all types of fasteners straight on or from an angle. And you can really apply a lot of torque with them to get that connection really tight and strong.

Ball-End Hex Wrench Set with Cheater BarTTraditional L-shaped allen wrenches can work for non-angled connections - but we recommend you buy ball-end hex wrenches and a cheater bar. A cheater bar is a hollow tube that you can put over the end of an L-shaped wrench to give you more leverage and power. Connecting t-slot bars requires a lot t-slot bars requires a lot of torque to tighten the fastener correctly, and the cheater bar will make this task easier.